Challenges & Solution
Challenges
Production delays were frequent due to lack of real-time visibility on raw material availability, causing last-minute planning changes on the shop floor. Batch traceability was weak, making it difficult to track materials to finished goods and handle quality issues efficiently. Inventory mismatches led to stockouts, overproduction and expiry-related losses. Procurement was reactive, with no clear link to production demand, resulting in excess or shortage of key ingredients. Manual recording in production and quality checks reduced accuracy and delayed reporting, impacting timely decisions.
Solution
We implemented an integrated ERP system connecting procurement, production, inventory and sales. MRP-based planning ensured accurate production scheduling and material availability. Batch and lot tracking enabled end-to-end traceability and faster quality control. Real-time inventory management improved stock accuracy and reduced wastage through expiry tracking. Procurement was automated based on demand and stock levels, ensuring optimal inventory. Digital quality checks and real-time reports improved operational visibility, efficiency and decision-making.